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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1244 (Engine Mechanical - 3.8L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement - Lower (L36) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the evaporative emissions (EVAP) canister purge solenoid.
    Fig 1: Removing Evaporative Emissions (EVAP) Canister Purge Solenoid (Lower L36)
    G02083537Courtesy of GENERAL MOTORS CORP.
    NOTE: The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.
  2. Remove the upper intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - UPPER  .
  3. Remove the generator brace. Refer to CHARGING SYSTEM or CHARGING SYSTEM in Battery.
  4. Remove the drive belt tensioner with the heater water bypass inlet pipe. Refer to DRIVE BELT TENSIONER REPLACEMENT  .
    Fig 2: >Removing Drive Belt Tensioner With Heater Water Bypass Inlet Pipe
    G02083538Courtesy of GENERAL MOTORS CORP.
  5. Remove the exhaust gas recirculation (EGR) outlet pipe bolt from the lower intake manifold.
  6. Remove the EGR outlet pipe from the lower intake manifold.
    Fig 3: Removing EGR Outlet Pipe
    G02083539Courtesy of GENERAL MOTORS CORP.
  7. Remove the radiator inlet hose from the water outlet housing. Refer to RADIATOR HOSE REPLACEMENT - INLET (3.8L) in Engine Cooling.
    Fig 4: Removing Radiator Inlet Hose From Water Outlet Housing
    G02083540Courtesy of GENERAL MOTORS CORP.
  8. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
    Fig 5: Disconnecting Electrical Connector
    G02083541Courtesy of GENERAL MOTORS CORP.
  9. Remove the generator brace bracket bolts.
  10. Remove the generator brace bracket.
    Fig 6: Removing Generator Brace Bracket Bolts
    G02083542Courtesy of GENERAL MOTORS CORP.
  11. Remove the lower intake manifold bolts.
  12. Remove the lower intake manifold.
    Fig 7: Removing Lower Intake Manifold
    G02083543Courtesy of GENERAL MOTORS CORP.
  13. Remove the lower intake manifold seals.
    Fig 8: Removing Lower Intake Manifold Seals
    G02083544Courtesy of GENERAL MOTORS CORP.
  14. Remove the lower intake manifold gaskets.
    Fig 9: Removing Lower Intake Manifold Gaskets
    G02083545Courtesy of GENERAL MOTORS CORP.
  15. If replacing the lower intake manifold, remove the water outlet housing bolt, stud and the water outlet housing.
  16. If replacing the lower intake manifold, remove the ECT sensor.
  17. Inspect the flatness of inlet flanges.
  18. Clean the intake manifold mating surfaces.
  19. Clean the intake manifold bolts and bolt holes of adhesive compound.
    Fig 10: Removing Water Outlet Housing And Thermostat
    G02083546Courtesy of GENERAL MOTORS CORP.
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